Process for obtaining iron from material containing iron oxides



PROCESS FUR OBTAENENG ERGN MATE- RIAL CGNTAWING LQGN GXKDES 7 Claims. (Cl. 751l) This invention relates to metallurgy and has for an object the provision of an improved method or process for producing metallic iron. More particularly, the invention contemplates the provision of a method or process which can be employed advantageously and economically ot produce high-grade metallic iron products from iron oxide-bearing materials, including various grades of iron ore such as the usual commercial ores and some ores of too low-grade to be treated commercially by means of heretofore customary methods or processes. The invention further contemplates the provision of a method or process which can be employed advantageously and economically to produce high-grade metallic iron products from various grades of iron ore through the use of various grades and types of carbonaceous reducing materials, including the usual commercial carbonaceous re ducing materials such as high-grade coal and coke and some carbonaceous reducing materials such, for example, as low-grade coal, wood and wood shavings of too poor quality metallurgically to be employed commercially in heretofore customary methods or processes for recovering iron from iron ores.

The invention utilizes heat contained in molten slag as the source of heat for promoting the reduction to the metallic state of iron contained in iron oxide. In a process of the invention, a charge comprising (1) iron oxidebearing material, (2) fluxing material for combining with gangue material contained in the iron oxide-bearing material, and (3) solid carbonaceous material is placed on the surface of a molten slag bath maintained at a temperature sufficiently high to provide substantially all of the heat required for melting the fluxing material and gangue material of the charge with the production of molten slag and for promoting and efiecting reduction of the iron of the iron oxide-bearing material of the charge by means of the carbonaceous reducing material of the charge with the production of molten metallic iron which is separated from the molten slag.

The invention permits the advantageous use of finely divided iron oxide-bearing material. In practicing the invention, finely divided iron oxide-bearing material is mixed with finely divided fluxing material and finely divided solid carbonaceous material to form a finely divided charge in which the components are intimately mixed. Intimate mixing of the components of the charge in finely divided forms promotes reduction of the iron of the iron oxide and facilitates the production of metallic iron and the recovery of the iron of the iron oxide-bearing material in the metallic state when the charge comprising the intimately mixed components is placed on the surface of the molten slag bath.

Iron oxide-bearing material containing iron in the ferrous state as ferrous oxide or in the ferric state as ferric oxide or in both the ferrous state and the ferric state may be employed in carrying out a process in accordance with the invention.

I prefer to employ combined electric arc and resistance heating (arc-resistance heating) for maintaining the Patented Sept. 10, 1957 slag bath at a temperature high enough to provide the heat required for melting the fiuxing material of the charge and for promoting and effecting reduction of the iron of the iron oxide-bearing material by means of the carbonaceous reducing material. Combined electric arc and resistance heating as employed in accordance with my invention involves the utilization of heat developed by one or more arcs extending between the arcing tips of the electrodes and the upper surface of a molten slag bath plus heat developed as the result of the resistance of the slag of the slag bath to the flow of electric current therethrough in passing or flowing between the electrodes.

When employing finely divided iron oxide-bearing material in forming a charge for reduction, I prefer to employ coal as the solid carbonaceous component of the charge, preferably, coal having coking or fusing properties, if available, and to heat the charge mixture to a temperature above the fusing or coking temperature of the coal prior to placing the charge on the surface of the molten slag bath. By employing coal and particularly coal having coking or fusing properties, I obtain several advantages. Thus, in using coal of any type as the solid carbonaceous reducing material, I effect a substantial reduction in the cost of the reducing material as compared with the cost of the coke commonly employed in iron reduction and recovery processes. In em-' ploying coal having fusing or coking properties and heating a charge mixture to a temperature above the fusing or coking temperature of the coal, I effect a more stable and, thus, a more effective intimate mixing of the components of the charge, for the coal upon fusing or coking functions as bonding material for the other components of the charge, and the tendency for the particles to separate or segregate, which characterizes loose mixtures of finely divided materials, is substantially completely avoided or eliminated. If desired, heating of the charge prior to placing it on the surface of a molten slag bath may be controlled to effect reduction to the ferrous state or to the metallic state of a portion of the iron of iron oxide contained in the charge. In practicing the invention when employing coal having fusing or coking properties, I prefer to carry out the heat treatment for the purpose of efiecting fusing or coking by passing the charge mixture through a rotary kiln or other suitable apparatus provided with suitable heating means wherein the tumbling of the charge will maintain the components of the charge in the desired intimately mixed state while they still are in the finely divided condition so that when fusing or coking takes place the components will become fixed in the desired intimate association, and a substantially homogeneous charge will be formed. Heating of the charge serves to effect vaporization of the volatile matter of the coal with the resulting two-fold advantage of providing volatile combustible material which can be and preferably is burned to provide a portion of the heat required for the heat treatment and avoiding the introduction into the electric furnace of the volatile matter ofthe coal with the attendant disadvantages resulting from gasification of the volatile matter within the elec tric furnace. Tumbling of the charge during the heat treatment for coking purposes insures the production of granular free-flowing material which can be subjected to the subsequent reducing treatment more advantageously than can lumpy material. Granular material promotes ease of handling and charging and, also, facilitates reduc tion. Generally, fusing or coking to a suitable extent or degree can be effected at a temperature of about 500 C. to 600 0.

Control of the preliminary heating of the charge to effect reduction of a portion of the iron of the iron oxide provides the additional advantage of reducing the danger covered electric arc furnace provided with one or more vertically extending electrodes. In operating such a furnace during the course of a process of the invention, I maintain the arcing tips of the one or more electrodes in sufficiently close proximity to the upper surface of the molten slag bath to inhibit dissipation of the arcdeveloped heat by reflection and to insure delivery to the molten slag bath of substantially. all of the arc-developed heat, and, I introduce charge material into the furnace and onto the surface of the molten slag bath therein at a rate such as tomaintain a low-pressure zone adjacent the arcing tips of the one or more electrodes.

The establishment of low-pressure zones results in avoidance of the frequent periodic blowing of the charge out of the furnace with the consequent danger to operators and disturbance of the operation that takes place because of unpredictable and uncontrollable rates or reaction and high pressure zones created by establishing deep beds of charge material around the electrodes in accordancewith heretofore customary practices.

Introduction of charge into the interior of the electric furnace is carried out at a rate such that it is deposited on the surface of the molten bath between the furnace walls and the electrodes without flowing into contact with the electrodes or at a rate such that it flows into contact with the electrodes and builds up around the electrodes to a depth of only a few inches.

The use of a covered are electric furnace providing combined electric arc and" resistance heating (arc-resistance heating) in accordance with the invention permits effective control of carbon in the molten iron produced. Thus, for example, if the amount of carbonaceous material contained in the charge introduced into the electric furnace is substantially equivalent to the amount required theoretically to reduce the iron of iron oxide contained in the charge, a molten metallic iron product containing.

not more than about two percent (2%) carbon by weight will be produced. By further restricting the amount of carbonaceous material in the charge to amounts lower than the amount required theoretically to reduce the iron of iron oxide contained in the charge, molten metallic iron products containing varying amounts of carbon from about two percent (2%) to less than one percent (1%) can. be produced. By incorporating in the electric furnace charge various amounts of carbon in excess of the amount required theoretically to reduce the iron of iron oxide, contained in the charge, molten metallic iron products containing carbon in amounts between two percent (2%) and the amounts contained in ordinary pig iron can be produced.

In carrying out a process in accordance with the invention, all of the carbonaceous material to be employed for reducti'on'of the iron of iron oxide in the electric furnace may be introduced into the furnace in admixture with the other components of the reducing charge, or a portion may be introduced into the furnace in admixture with the. other components of the total charge, and a portion may be introduced into the are electric furnace separately.

Dissipation of the arc-developed heat by'reflection may be inhibited satisfactorily by maintaining arcs not greater in length than about one-half inch. A Zone of suitably low pressure adjacent to the one or more electrodes may be maintained by limiting the depth of charge material immediately adjacent to'the one or more electrodes to a maximum of twelve (12) inches.

In operating the electric furnace employing combined 7,

electric arc and resistance (arc-resistance) heating in accordance with the invention, the tips of the one or more electrodes preferably are maintained in positions with respect to the vertical ranging between about one-half inch /z) above the surface of the slag bath and two inches (2") below the surface ofthe slag bath. Immersion or penetration of the one or more electrodes in or into the molten slag bath to a depth short of that which Will permit wetting of the electrodes by the slag will permit retention of the arc-resistance heating character of the operation with utilization constantly of arc-developed heat plus heat developed by the resistance of the slag of the slag bath to the flow of electric current therethrough between the electrodes. Tapping of the furnace is controlled to maintain in the furnace a slag bath having a depth not less than about three inches (3 in order always to maintain between the arcing tips of the electrodes and the metal beneath the slag bath a layer of slag at least one inch (1") in depth.

Maintenance constantly within a furnace of a molten slag bath of proper depth with a layer of molten slag disposed between the arcing tips of the electrodes and molten metal beneath the slag bath permits the use of substantially constant voltages at substantially constant power factor and provides for smooth furnace operations.

Through operation of the furnace constantly as an arc-resistance furnace with short arcs and constant or substantially fixed resistance through control of the depth of the molten slag bath and the positions of the electrodes,

the temperature of the molten slag bath is desired for a particular operation, the voltage is increased or decreased and the electrode regulator is adjusted to maintain the arc length within the desired range (equivalent to the arc length established by maintaining the arcing tips of the electrodes in a position relatively to the vertical between about one-half 0/2") inch above the surface of the slag bath and two inches (2") below the surface of the slag bath). In following this procedure, the resistance is maintained constant and, consequently, the power input is increased or decreased.

I prefer to employe an arc electric furnace having a holding capacity of fifty (50) to one hundred or more tons of molten iron and, in carrying out a process in accordance with the invention, I prefer to tap the furnace at intervals when the amount of molten iron in the furnace is equalto or substantially equal to the holding capacity of the furnace. The production of such large batches provides molten metal in quantities large enough to contain sufficient sensible heat to permit transfer in ladles to casting locations or other furnaces without objectionable skull formation occurring.

In accordance with the. invention, the iron oxide-bearing material maybe subjected to one or moretreatments involving the use of heat for effecting the reduction of iron to the metallic stateand the production of a molten metallic iron product and a molten slagproduct. Thus, for example, (1) the iron oxide-bearingmaterialrnay be incorporated in a solid charge comprising carbonaceous reducing material and suitable fluxing material, and

solid charge. without preheating or withoutpreheating to degree that would alter materially its. initial composi tion'with. respect to ironToxide, may be placed on the surface of a molten slag bath maintained at a tempera- J ture sufiiciently high to provide the-heat required to effect adesired economic or substantially complete reduction of iron with the production of molten metallic iron and molten slag; or (2) a charge comprising the iron oxidebearing material, carbonaceous reducing material and suitable fluxing material may be subjected to a preliminary heating treatment to effect reduction to the metallic state of a portion of the iron of the iron oxide-bearing material with the production of a granular product, and the granular product of the preliminary heating treatment may be placed on the surface of a molten slag bath maintained at a temperature suificiently high to provide the heat required to effect melting of metallic iron produced in the preliminary heating treatment and a desired economic or a substantially complete reduction of residual un-reduced iron of the iron oxide-bearing material with the production of molten metallic iron and molten slag; or (3) in the treatment of iron oxide-bearing material containing one or more non-ferrous elements such as copper, nickel, cobalt and iron, a solid charge comprising the iron oxide-bearing material, suitable fluxing material and carbonaceous reducing material in a limited amount sufiicient to effect the reduction to the elemental state of the non-ferrous element may be placed directly (without being subjected to a preliminary heating treatment), or after having been subjected to a preliminary heating treatment, on the surface of a molten slag bath maintained at a temperature sufficiently high to provide the heat required to effect desired reduction and melting with the production of a molten metallic product containing the non-ferrous element or elements and a molten slag product containing iron oxide, and the molten slag product together with sutficient carbonaceous reducing material to effect reduction of the desired amount of iron of the iron oxide contained in the slag may be placed in a furnace containing a molten slag bath maintained at. a temperature sufiiciently high to provide the heat required for reduction of the iron of the iron oxide With the production of molten metallic iron and molten slag.

Preferably, the furnace into which is placed the molten iron oxide-bearing slag resulting from the operation carried out to produce a metallic product containing nonferrous metals is an arc-electric furnace provided with one or more vertically extending electrodes and operated in accordance with the principles and practices hereinbefore set forth with respect to such factors as control of arc length, relative positions of arcing tips of electrodes and surfaces of molten slag baths, inhibition of dissipation of arc-developed heat and utilization of arc-developed heat plus heat developed as the result of resistance of the slag to the flow or passage therethrough of electric current between electrodes.

Preliminary heating of a charge to effect granulation with controlled reduction of iron to the metallic state, in accordance with the invention, may be carried out at temperatures between about 500 C. and the melting point of the metallic iron produced. Preferably, reduction is carried out at a temperature in the upper portion of the range extending from 500 C. to the melting point of metallic iron that may be produced. A suitable tem perature for promoting reduction of iron with the production of a suitable granular product is one just at or just below the fusing temperature of the slag-a temperature, preferably, at which sufficient softening of the charge undergoing the reduction treatment to produce a sintered or fritted, free-flowing granular product takes place. Adjustment of the proportions of slag-forming materials present in the charge may be carried out advantageously to provide for effective reduction at sintering temperatures or temperatures of incipient fusion in the range of about 1100 C. to 1300 C.

A preferred complete process of the invention comprises two or more steps, depending on the composition of the ore treated, including a preliminary low-temperature reduction step and a melting step. When iron is the only economically recoverable metallic element present in the ore, or, when a single metallic product comprising the iron of the ore alone or comprising the iron and any other metallic element present in the ore is sought, the preferred complete process of the invention for the production of a metallic iron-bearing product may consist of a low-temperature reduction step for the production of a sintered granular product comprising reduced metallic iron and a melting and reducing step designed to receive and treat the sintered product for the production of a molten bath comprising separable layers of molten metal and molten slag.

When a process of the invention is employed for the treatment of an iron ore containing one or more of the non-ferrous metals, nickel, cobalt, and copper, melting and reducing may be carried out in two stages in the first of which, a molten metallic product containing a large proportion or substantially all of the one or more nonferrous metals and a small amount of the iron is produced and in the second of which a molten metallic product containing the remainder of the reduced metallic iron is produced. When a process of the invention is employed for the treatment of a high-phosphorus iron ore, a procedure similar to that employed in separating nonferrous metals may be employed to produce a metallic product comprising some iron and high in phosphorus in a first or preliminary melting and reducing stage and a product comprising the remainder of the iron in a second or principal melting and reducing stage.

For fluxing ore to be treated and producing a suitable reduction charge in accordance with the invention, I incorporate in the charge iron ore, solid carbonaceous material and fluxing material such as lime (as such or in the form of limestone) and silica, as required, to flux the gangue of the ore and the ash-forming constituents or components of the carbonaceous material. The components of the charge are selected to provide for the production of a slag having a lime-silica molecular ratio in the range, 0.7 to 3.0 molecule of CaO to 1.0 molecule of SiOz. Any suitable lime-silica ratio may be employed in any modification of the process of my invention, but I prefer to employ ratios in the range of 0.7 to 1.5 CaO to SiOz for selective reduction of iron to remove phosphorous, sulphur, arsenic, cobalt, nickel etc., and 1.5 to about 2.0 for reduction and refining to iron in the second stage or where high grade iron ores are used in the initial charge and relatively no impurities are involved. In general, when the electric furnace is used for melting and reducing, the higher ratios of CaO to SiOz may be useful, depending on whether a finished steel or a pig iron end product is desired.

I may incorporate in the charge to be subjected to a preliminary reducing and sintering treatment for the production of a granular product all or any desired portion of the total amount of solid carbonaceous material required, and I may so control the reducing and sintering treatments, with respect to times, temperature and additions of fluxing materials, as to effect reduction of iron by means of all or any desired proportion of the carbonaceous material. When an amount of solid carbonaceous material less than the amount required to effect complete reduction is employed, additional solid carbonaceous reducing material may be added to the charge employed in a subsequent melting and reducing operation. When the reducing and sintering treatment is so controlled as to effect reduction by means of a portion only of the solid carbonaceous material, further reduction will be effected in the melting and reducing stage following the reduction and sintering treatment. In a preferred process of the invention, I incorporate in the charge to be subjected to the preliminary reducing and 'sintering treatment solid carbonaceous reducing material in amount suflicient to reduce all of the iron of the iron ore of the charge, and I so conduct the preliminary reducing and sintering treatment as to effect reduction 7 of a large proportion of'the iron, complete rednctionnot being highly essential sincefurther reduction will take place in the following melting andreducing step.

In forming a. charge in accordance with the invention, I' prefer to mix. intimately the various components including the ore, solid carbonaceous material, and fluxing material. Thecomponents may be crushed to. any suitable degree of fineness and any suitable mixing'methods and apparatus may be employed. For mosteffectivembn ing, I prefer to grind together in asuitable mill the various components'of the charge; A charge in which all of the materials. are finelydivided and a large proportion of the particles are small enough to pass a IO-mesh screen permits effective sintering and reduction with the production of a granular product. Charges comprising smallerparticles permitmoreintimate contact of components and provide for more rapid sintering and reduction. 7

Sintering preferably is carried out at a temperature such. that the lime employed for fluxing purposes may enter into chemical combination with silica present in the charge. The lime thus is placed in position to function most effectively as a fiuxing agent during the reduction and melting treatments. The sintering treatment may also result in the production of calcium compounds of iron which are more readily reducible than the compounds of iron contained in the original iron ore.

The preliminary reducing and sintering treatment accomplishes a substantial amount of the total work required to be done to recover metallic iron from iron ore. Thus, for example, a large proportion of the iron may be reduced, slag-forming materials are placed in positions where they may function with high efiiciencies to form molten slag products in the subsequent melting treatment, solid carbonaceous material is placed in position and condition to function elfectively in the subsequent melting and reducing treatment when only partial reduction of iron is accomplished in the preliminary reducing and sintering operation, and there is delivered to the melting furnace a granular sintered product which can be raised rapidly to and through the slag and metal melting temperatures to accomplish eflectively completion of the work of reducing, melting and separation of slag and metal products remaining to be done to produce the useful metal.

Any suitable type of furnace may be employed for carrying out the reducing and sintering treatment. I prefer to employ a rotary kiln of the type of a cement kiln ora traveling hearth type sintering furnace, such, 7

for example, as the Dwight-Lloyd sinten'ng furnace or a tunnel kiln.

When operated efficiently for the recovery of iron alone, my process becomes a two stage process in which the reduction and slag formation stage is carried out in alow-temperature range to produce a partially or wholly sintered and partially or wholly reduced product and the melting and refining stage is carried out in a high-temperature range in high-temperature equipment to produce molten slag and a molten iron product of any desired composition.

The process of my invention may be operated advantageously to utilize hi h-phosphorus ores by using two electric melting and reducing furnaces. In the first furnace, a partially reduced sinter containing iron oxide and some metallic iron is melted to produce a small amount of iron high in phosphorus. The slag from this furnace is tapped into a second furnace and the reduction of the iron oxide com leted with coke or coal to produce low phosphorus pig iron or steel as the case may be. The high-phosphorus iron is tapped from the first furnace and cast into pigs. The operation may be carried out in the same furnace, if desired, by tapping out the high-phosphorus iron first and then completing the reduction of the balance of the iron oxide in the slag to produce low-phosphorus iron or steel.-

ass ss;

s. The process. of the invention, unlike other processes, is capable ofhigh-tonnage production. A rotary'kilniof' 180 feet length and. Sfeet diameter, can bowed to produce at least 240tons and as much as 500: tons ormorc of iron per day; This kiln can be. used to' feed one or more melting furnaces. It can also be used to heat scrap 7 iron and steel. That is, fine scrap,,such asshort turnings or shredded turnings, may be added to the charge and be preheated before entering the melting furnace. Large scrap rnay be added into the melting furnace directly.

Larger kilns, the 500 to 700 foot length, would, of' course, come up to production equalling the blast fur-' nace. Such kilns would require several melting furnaces of normal size.

Many attempts have been made to accomplish electric furnace smelting of pigiron, but they have not been economical compared to the blast furnace. In my process, the electric furnace is economical even at the high cost of power in the steel centers of the United States, because the amount of power required is reduced substantially merely to that required for refining, which, in good. practice, may be as low as 700 kilowatt hours per ton of metal.

My process further makes possible the operation of larger electric furnaces. The usual electric steel furnace, operating on scrap, operates at a low power factor because of the largeamount of inductance required to make the operation smooth. This low power factor is a heavy load on the power generating facilities. In my process, the melting and reducing furnace can readily be designed to operate at. power factor and thereby increase the efficiency of melting and reduce the burden on the power generating facilities. The process will make more power available through the more eflicient use of the present capacity. This is true because the melting takes place at all times under a fairly heavy slag. Molten slag is tapped off at about the same rate at which it is produced, after formation of a suitable fluid slag covering for the metal, so that there is maintained at all times a sufliciently heavy slag layer to provide for efficient melting and for carrying the power into the furnace at high etliciency.

The invention will be better understood from a consideration of the following description in conjunction with the accompanying drawings in which:

Fig. 1 is' an elevation, partly in section, of apparatus suitable for use in carrying out a process of the invention;

Fig. 2 is a sectional elevation taken substantially along the line 2-2 of Fig. 1; and

Fig. 3 is a sectional plan taken substantially along the line 33 of Fig. 2.

The apparatus. shown in the drawings comprises a covered electric furnace 10 provided with three substantially identical electrodes 11 supported by means of conventional holders (not shown) and electrically connected in circuit with conventional control and power supplying means (not shown), including transformer secondaries, voltage regulating means and automatic electrode positioning or adjusting means.

The are electric furnace 10 is rectangular in horizontal cross-section and comprises a hearth or bottom portion 12, side walls 13, and walls 14 and a roof 15, all formed of appropriate refractory materials. An electric furnace of any suitable horizontal cross-sectional configuration may be employed.

The roof 15 is provided with suitable openings through which the electrodes 11 extend and which permit vertical movement of the electrodes in accordance with operational demands and characteristics. The spaces between the electrodes and the edges of the openings through which the electrodes extend or project may be provided with any suitable conventional packing or sealing means to inhibit or restrict 'or prevent the flow of gases between the interior and the exterior of the furnace without interfering with the necessary vertical movements of the electrodes.

Hoppers 16 having their lower portions extending through and sealed in openings in the roof 15 are provided adjacent the outer side edges and the end edges of the electric furnace in alinement with the electrodes to permit the introduction of charge materials 17 into the interior of the furnace.

The portions 18 of the side and end walls of the furnace immediately beneath the hoppers 16 preferably are so designed as to provide a slope corresponding to or equivalent to the angle of repose of the charge material. Preferably, the sloped portions of the walls are stepped or terraced, as shown in the drawings, to provide for the deposition and retention thereon of protective coatings of charge material.

A conduit assembly 19 communicates with the interior of the electric furnace 10 through an opening in the roof 15, with the interior of the rotary kiln 20 and with an air inlet 26 to permit the collection and utilization carbon monoxide produced in the process.

The apparatus shown in Fig. 1 of the drawings includes the rotary kiln 20 communicating with a stationary dust collecting chamber 21 and provided with a hopper and chute or conduit arrangement 22 for introducing charge material thereinto at or about its point of highest elevation. At the opposite end of the rotary kiln, means are provided for introducing a combustible mixture of air and carbon monoxide produced in the electric furnace to permit utilization of the carbon monoxide for pro-heating charge material to be introduced into the electric furnace. The dust collecting chamber 21 is provided with a rotary sealing device 25 which permits withdrawal of collected dust particles without permitting ingress of air or other gas from the exterior.

A storage hopper or chamber 23 is provided for receiving the charge material from the rotary kiln, and a screw conveyor assembly 24 is provided for delivering heated charge material from the storage chamber 23 to the furnace hoppers 16 from where it is introduced into the electric furnace.

As indicated in the drawings and as described above, the rotary kiln 20 preferably is operated at an elevated temperature in the range 500 C. to 1300 C. to efiect agglomeration of a finely divided mixture of ore (iron oxide-bearing material), fluxing material such as lime (CaO) and coal with the production of a free-flowing granular product, heat being provided through combustion of the carbon monoxide proudced in the are electric furnace and the volatile matter of the coal distilled from the coal in the kiln.

As contemplated by the invention, the kiln may function primarily as a cooling device in which hot gases from the are electric furnace containing carbon monoxide are cooled and conditioned for subsequent treatment or utilization through contact with relatively cold (or lowtemperature) charge materials within the kiln, in which event air preferably would be excluded from the interior of the kiln.

Alternatively, provision may be made for by-passing the kiln and conducting the carbon monoxide directly to one or more other points of util'mation. When air and the hot gases containing carbon monoxide are excluded from the interior of the kiln, the kiln functions primarily as a mixing device for producing an intimately mixed char e of finely divided iron oxide-bearing material, fluxing material and carbonaceous material which may be delivered to the are electric furnace at substantially atmospheric temperature without granulation or agglomeration. At relatively low temperatures produced by the use of controlled relatively high rates of passage of charge materials through the kiln and controlled rates of heat development, the kiln functions primarily as a nodulizing low fusing or coking temperature acts as the bonding agent. At relatively high temperatures corresponding to sintering temperatures or temperatures of incipient fusion produced by the use of controlled relatively low rates of passage of charge materials through the kiln and controlled rates of heat development, the kiln functions as a reducing chamber for reducing a portion of the iron of the iron oxide-bearing material of the charge and, also, as a nodulizing or granulating device in which the softened non-carbonaceous materials or minerals of the charge function as the bonding agent or agents.

Any desired number of storage chambers 23 of any suitable size or sizes may be provided to permit storage of any desirable amount of pre-formed charge mixture suitable for introduction into the are electric furnace 10. The storage chamber or chambers may be insulated to provide for retention of sensible heat of charge mixtures delivered thereinto from the rotary kiln, and charge mixtures may be withdrawn from storage and introduced into the are electric furnace at any suitable temperature between atmospheric temperature and the temperature of discharge from the rotary kiln when heating of charge mixture is carried out in the rotary kiln. Reduction of a portion of the iron of the iron oxide in the rotary kiln reduces the reduction burden which must be imposed on the arc electric furnace with a resulting increase in the capacity of the arc electric furnace to produce molten iron. Retention of relatively high-temperature charge mixture in storage permits reduction of iron of iron oxide by means of carbonaceous material to proceed, thus providing for utilization of the sensible heat with consequent further reduction of the reducing burden imposed on the are electric furnace and further increase in the capacity of the arc electric furnace to produce molten metallic 1ron.

Apparatus of the type illustrated in the drawings may be utilized for the treatment of charges of any suitable types comprising iron oxide-bearing material, carbonaceous reducing material and fluxing material. Thus, for example, the apparatus may be employed in treating a charge mixture comprising .as components iron oxidebearing ore, limestone for fluxing and coal for reduction of the compositions and in the proportions indicated below.

COMPOSITIONS OF COMPONENTS Iron oxide-bearing ore A charge of the above-indicated composition is introduced into the rotary kiln 20 through the hopper and chute arrangement 22. The charge preferably comprises or consists largely of solid particles small enough to pass a 4-mesh screen and they preferably are intimately mixed together prior to the introduction of the charge into the may be employed to effect intimate mixing of the particles of the charge. The kiln may be operated with or without utilization of heat to effect heating of the charge. When preliminary heating of the charge prior to its introduction into the are electric furnace is not desired, the components of the charge may be mixed in any suitable apparatus other than the kiln and the mixed charge may be introduced directly into the storage hopper 2 3 and conveyed from there to the furnace charging hoppers 16 by means of the screw conveyor 24, or, the mixed charge may be introduced directly from the mixing apparatus into the furnace charging hoppers 16.

When heating of the charge is desired in order to eifect'the production of a granular free-flowing product in which particles of the components are bonded together and held in intimate contact, heatingrmay be accomplished by the introduction into the kiln and ignition therein of a combustible mixture of atmospheric air' and carbon monoxide produced in the are electric furnace.

10 through the conduit arrangement 19. When combustible volatile matter of the coal is to be oxidized to provide additional heat, air is supplied in the amount required for oxidation of such volatile combustible matter in addition to the amount required for oxidation of the carbon monoxide. If additional heat should be required or desired, it may be supplied from any suitable source in any suitable manner. Usually, combustion of the carbon monoxide and the combustible matter of high-volatile matter coal, coupled with control of the rate of passage of the charge through the kiln, will provide all heat required for heating the charge to the highest desirable temperatures, such as sintering temperatures or temperatures of incipient fusion of the non-carbonaceous mineral particles in the range of about 1100 C. to 1300 C. Reduction of iron oxide initiated in the rotary kiln will continue during the period of retention in the storage hopper of charge mixtures introduced thereunto at temperatures as high as and substantially lower than 1200 C.

Charge material discharged from the rotary kiln 29 into the storage hopper 23 is conducted at a controlled rate by means of the screw conveyor 24 to the charging hoppers 16 from where it flows under the influence of gravity into the are electric furnace and onto the surface of the molten slag bath therein. Figs. 1 and 2 of the drawings show two positions of the upper surface of the molten slag bath and two depths of molten slag and metal, described by legends applied to Fig. 1 as slag to metal, before tap and after tap. In Figs. 1 and 2, the electrodes are shown in one position only, the position they occupy after tapping when. the volume of molten material in the furnace is relatively small. As indicated, the arcing tips of the electrodes are. disposed at substantially the same level as the upper surface of the molten slag after tapping with short arcs shown as extending beneath the upper surface of the molten slag bath which condition exists because of electrical pressure created and maintained as long as the positions of the arcing tips are not sufficiently below the upper surface of the slag bath to permit wetting of. the electrodes by the molten slag. The electrodes have been shown in position with respect to the upper surface of the molten slag bath after tapping only in order to avoid confusion and promote clarity. It will be understood that operating positions of the arcing tips of the electrodes before tapping will be the same or substantially the same with respect to the upper surface of the molten slag bath as shown with respect to the upper surface of the slag bath after tapping.

inthe operation of the are electric furnace 10, reduction of iron of the iron oxide of the charge material 17 placed on the surface of the molten slag bath is effected substantially entirely byheat contained in the molten slag bath and delivered thereto by means of arc-developed heat and resistance developed heat resulting from resistance to the 12 flowtheret-hrough' of electric current passing. between electrodes.

I claim: g

1. In a'process for producing metallic iron by reduction of the iron of iron oxide-bearing material containing gangue material, the improvement which comprises plac ing a charge comprising the iron oxide-bearing material, fluxing material and solid carbonaceous reducing material on the surface of a molten slag bath in a covered open-arc electric furnace provided with one or more vertically extending electrodes, maintaining the slag bath' at a temperature sufliciently high by means of combined electric arc and resistance heating to provide substantially all of the heat required for melting the fluxing material and gangue material of the charge with the production of molten slag and for promoting and effecting reduction of the iron of the iron oxidebearing material of the charge by means of the carbonaceous reducing material of the charge With the production of molten metallic iron, and separating the molten metallic iron from the molten slag, operation of the furnace during the course of the process being controlled to maintain the arcing tips of the one or more electrodes in sufficiently close proximity to the upper surface of the molten slag bath to inhibit dissipation of arc-developed heat by reflection and to insure delivery directly to the molten slag bath of substantially all of the arc-developed heat, and the rate of introduction of charge material into the furnace and onto the surface of the molten slag bath therein being controlled to maintain a low-pressure zone adjacent the arcing tips of the one or more electrodes.

2. In a process for producing metallic iron by reduction of the iron of iron oxide-bearing material containing gangue material, the improvement which comprises placing a finely divided charge in the form of an intimate mixture comprising the iron oxide-bearing material, fluxing material and solid carbonaceous reducing material on the surface of a molten slag bath in a covered open-arc electric furnace provided with one or more vertically extending electrodes, maintaining the slag bath at a temperature sufliciently high by means of combined electric arc and resistance heating to provide substantially all of the heat required for melting the fiuxing material and gangue material of the charge with the production of molten slag and for promoting and effecting reduction of the iron of the iron oxide-bearing material of the charge by means of the carbonaceous material of the charge with the production of molten metallic iron, and separating the molten metallic iron from the molten slag, the amount of carbonaceous reducing material included in the charge introduced into the furnace and placed on the surface of the molten slag bath being not substantially greater than that required for reduction and being insuflicient to introduce. into the metallic iron produced carbon in an amount greater than two percent (2%) by weight, operation of the furnace during the course of the process being controlled to maintain the arcing tips of the one or more electrodes in sufliciently close proximity to the upper surface of the molten slag bath. to inhibit dissipation of arc-developed heat-by refiection and to insure delivery directly to the molten slag bath of substantially all of the arc-developed heat, and the rate of introduction of charge material into the furnace and onto the surface of the molten slag bath therein being controlled to maintain a low-pressure zone adjacent the arcing tips of one or more electrodes.

3. In a process for producing metallic iron by reduction of the iron of iron oxide-bearing material containing gangue material, the improvement which comprises placing a finely divided charge in the form of an intimate mixture comprising the iron oxide-bearing material, fluxing material and solid carbonaceous'reducing material on the surface of a molten slag bath in a covered open-arc electric furnace provided withv one or more vertically ex-' tending electrodes, maintaining the slag bath at a temperature sufliciently high by means of combined electric arc and resistance heating to provide substantially all of the heat required for melting the fluxing material and gangue material of the charge with the production of molten slag and for promoting and effecting reduction of the iron of the .iron oxide-bearing material of the charge by means of the carbonaceous material of the charge with the production of molten metallic iron, and separating the molten metallic iron from the molten slag, operation of the furnace during the course of the process being controlled to maintain the arcing tips of the one or more electrodes in sufliciently close proximity to the upper surface of the molten slag bath to provide for the maintenance of arcs not greater in length than about onehalf inch thus to inhibit dissipation of arc-developed heat by reflection and to insure delivery directly to the molten slag bath of substantially all of the arc-developed heat, and the rate of introduction of charge material into the furnace and onto the surface of the molten slag bath therein being controlled to maintain a low-pressure zone adjacent the arcing tips of the one or more electrodes by limting the depth of charge material immediately adjacent the electrodes to a maximum of twelve (12) inches.

4. A process for producing metallic iron by reduction of the iron of iron oxide-bearing material containing gangue material which comprises heating a finely divided mixture of the iron oxide-bearing material, fluxing material and coal having softening, fusing or coking properties to a temperature above the softening, fusing or coking temperature of the coal and thus forming a charge of granular material having iron oxide-bearing material, fiuxing material and solid carbonaceous reducing material intimately mixed therein, placing the charge of granular material on the surface of a molten slag bath in a covered open-arc electric furnace provided with one or more vertically extending electrodes, maintaining the slag bath at a temperature sufficiently high by means of combined electric arc and resistance heating to provide substantially all of the heat required for melting the fluxing material and gangue material of the charge with the production of molten slag and for promoting and eflecting reduction of the iron of the iron oxide-bearing material of the charge by means of the carbonaceous material of the charge with the production of molten metallic iron, and separating the molten metallic iron from the molten slag, operation of the furnace during the course of the process being controlled to maintain the arcing tips of the one or more electrodes in positions with respect to the vertical between about one-half /2") inch above the upper surface of the molten slag bath and about two (2) inches below the upper surface of the molten slag bath to inhibit dissipation of arc-developed heat by refiection and to insure delivery directly to the molten slag bath of substantially all of the arc-developed heat, and the rate of introduction of charge material into the furnace and onto the surface of the molten slag bath therein being controlled to maintain a low-pressure zone adjacent the arcing tips of the one or more electrodes by limiting the depth of charge material immediately adjacent the electrodes to a maximum of twelve (12) inches.

5. In a process for producing metallic iron by reduction of the iron of iron oxide-bearing material containing gangue material, the improvement which comprises placing a finely divided charge in the form of an intimate mixture comprising the iron oxide-bearing material, fluxing material and solid carbonaceous reducing material on the surface of a molten slag bath in a covered open-arc electric furnace provided with one or more vertically extending electrodes, maintaining the slag bath at a temperature sufiiciently high by means of combined electric arc and resistance heating to provide substantially all of the heat required f r melting the fluxing material and gangue material of the charge with the production of molten slag and for promoting and effecting reduction of the iron of the iron oxide-bearing material of the charge by means of the carbonaceous material of the charge with the production of molten metallic iron, and separating the molten metallic iron from the molten slag, operation of the furnace during the course of the process being controlled to maintain the arcing tips of the one or more electrodes in positions with respect to the vertical between about one-half /2) inch above the upper surface of the molten slag bath and about two (2) inches below the upper surface of the molten slag bath and to maintain between the arcing tips of the electrodes and molten iron beneath the molten slag bath a layer of slag at least one inch in depth, thereby to inhibit dissipation of arc-developed heat by reflection to insure delivery directly to the molten slag bath of substantially all of the arc-developed heat and to maintain the arc-resistance heating character of the operation, the rate of introduction of charge material into the furnace and onto the upper surface of the molten slag bath therein being controlled to maintain a low-pressure zone adjacent the electrodes by limiting the depth of charge material immediately adjacent the electrodes to a maximum of twelve (12) inches.

6. A process for producing metallic iron by reduction of the iron of iron oxide-bearing material containing gangue material which comprises heating a finely divided mixture of the iron oxide-bearing material, fluxing material and coal having softening, fusing or coking properties to a temperature above the softening, fusing or coking temperature of the coal and thus forming a charge of granular material having iron oxide-bearing material, fluxing material and solid carbonaceous reducing material intimately mixed therein, placing the charge of granular material on the surface of a molten slag bath in a covered open-arc electric furnace provided with one or more vertically extending electrodes, maintaining the slag bath at a temperature sufficiently high by means of combined electric arc and resistance heating to provide substantially all of the heat required for melting the fiuxing material and gangue material of the charge with the production of molten slag and for promoting and efiecting reduction of the iron of the iron oxide-bearing material of the charge by means of the carbonaceous material of the charge with the production of molten metallic iron, and separating the molten metallic iron from the molten slag, the amount of carbonaceous reducing material included in the charge introduced into the furnace and placed on the surface of the molten slag bath being not substantially greater than that required for reduction to the metallic state of iron contained in the charge and being insufiicient to introduce into the metallic iron produced carbon in an amount greater than two percent (2%) by weight, operation of the furnace during the course of the process being controlled to maintain the arcing tips of the one or more electrodes in positions with respect to the vertical between about one-half inch /2) above the upper surface of the molten slag bath and about two inches (2") below the upper surface of the molten slag bath and to maintain between the arcing tips of the electrodes and molten iron beneath the molten slag bath a layer of slag at least one inch in depth, thereby to inhibit dissipation of arc-developed heat by reflection to insure delivery directly to the molten slag bath of substantially all of the arc-developed heat and to maintain the arc-resistance heating character of the operation, the rate of introduction of charge material into the furnace and onto the upper surface of the molten slag bath therein being controlled to maintain a low-pressure zone adjacent the electrodes by limiting the depth of charge material immediately adjacent the electrodes to a maximum of twelve inches (12).

7. In a process for producing metallic iron by reduction of the iron of iron oxide-bearing material including gangue material and one or more non-ferrous elements of the class consisting of arsenic, nickel, cobalt, copper, sulfur and phosphorus, the improvement that comprises I5 heating a charge comprising said iron oxide-bearing material and fluxing material under reducing conditions in the presence of a controlled amount of solid carbonaceous reducing material to efliect reduction of substantially all of the one or more non-ferrous elements and at least a portion of the iron oxide to produce (1) molten iron produced by the reduction of a portion of the iron oxide and containing substantially all of the one or more nonferrous elements in reduced form and (2) a molten slag product comprising the remaining iron oxide of the charge, fluxing material of the original charge, and gangue material of the charge, separating and removing the molten metallic iron containing the non-ferrous elements from the molten slag product, placing the slag product together with additional carbonaceous reducing material on the surface of a molten slag oath maintained in a covered open-arc electric furnace, maintaining said slag bath by combined arc-resistance and slag-resistance heating at a temperature sufficiently high to provide all of the heat required for melting the components of the slag productandfor promoting and effecting reduction of the iron oxide, content thereof With the production of molten metallic ironsubstantially free of non-ferrous elements and molten residual slag, and separating and recovering the molten metallic iron from the molten slag.

References Cited in the fileof this patent UNITED STATES PATENTS 711,738 Ruthenburg Oct. 21, 1902 1,857,779 Flodin May 10, 1932 1,901,367 Gustafsson Mar. 14, 1933 2,098,176 Udy Nov. 2, 1937 2,397,993 Urquhart Apr. 9, 1946 2,523,092 Bryk et al. Sept. 19, 1950 2,549,994 Udy Apr. 24, 1951 2,582,469 Udy Jan; 15, 1952 FOREIGN PATENTS 22,236 Great Britain of 1911 

1. IN PROCESS FOR PRODUCING METALLIC IRON BY REDUCTION OF THE IRON OF IRON OXIDE-BEARING MATERIAL CONTAINING GANGUE MATERIAL, THE IMPROVEMENT WHICH COMPRISES PLAING A CHARGE COMPRISES THE IRON OXIDE-BEARING MATERIAL, FLUXING MATERIAL AND SOLID CARBONACEOUS REDUCING MATERIAL ON THE SURFACE OF A MOLTEN SLAG BATH IN A COVERED OPEN-ARC ELECTRIC FURNACE PROVIDED WITH ONE OR MORE VERTICALLY EXTENDING ELECTRODES, MAINTAINING THE SLAG BATH AT A TEMPERATURE SUFFICIENTLY HIGH BY MEANS OF COMBINED ELECTRIC ARC AND RESISTANCE HEATING TO PROVIDE SUBSTANTIALLY ALL OF THE HEAT REQUIRED FOR MELTING THE FLUXING MATERIAL AND GANGUE MATERIAL OF THE CHARGE WITH THE PRODUCTION OF MOLTEN SLAG AND FOR PROMOTING AND EFECTING REDUCTION OF THE IRON OF THE IRON OXIDE-BEARING MATERIAL OF THE CHARGE BY MEANS OF THE CARBONACEOUS REDUCING MATERIAL OF THE ND CHARGE WITH THE PRODUCTION OF MOLTEN METALLIC IRON, AND SEPARATING THE MOLTEN METALLIC IRON FROM THE MOLTEN SLAG OPERATION OF THE FURNACE DURING THE COURSE OF THE PROCESS BEING CONTROLLED TO MAINTAIN THE ARCING TIPS OF THE ONE OR MORE ELECTRODES IS SUFFICIENTLY CLOSE PROXIMITY TO THE UPPER SURFACE OF THE MOLTEN SLAG BATH TO INHIBIT DISSIPATION OF ARC-DEVELOPED HEAT BY REFLECTION AND TO INSURE DELIVERY DIRECTLY TO THE MOLTEN SLAG BATH OF SUBSTANTIALLY ALL OF THE ARC-DEVELOPED HEAT, AND THE RATE OF INTRODUCTION OF CHARGE MATERIAL INTO THE FURNACE AND ONTO THE SURFACE OF THE MOLTEN SLAG BATH THEREIN BEING CONTROLLED TO MAINTAIN A LOW-PRESSURE ZONE ADJACENT THE ARCING TIPS OF THE ONE OR MORE ELECTRODES. 